Artificial leather and methob of producing it



R. F. DYER.

ARTIFICIAL LEATHER AND METHOD OF PRODUCING IT.

APPLICATION FILED AUG-I4, I9I8.

1,308,231. Patented July 1, 1919.

' Ir/vEr/far- UNITED STATES PATENT ()FFIGE.

RICHARD "Dyna, OF PROVIDENCE, nnonn ISLAND, ASSIGNOR To GEORGE n. G-ABB,

0F BLOOMFIELD, CONNECTICUT.

ARTIFICIAL LEATHER AND METHOD OF PRODUCING IT.

specification of Letters Patent.

Patented July 1, 1919.

Application filed August 14,1818. Serial No. 249,908.

. State of Rhode Island, have invented certain new and useful Improvements in Artificial Leather and Method of Producing It, of which the following is a specification.

This invention relates to a method for the production of artificial leather. The leather substitute may take divers different forms; it may be plain, embossed, patent, enameled or japanned which are merely several illustrations. Artificial leather made in accordance with the method may be put to various commercial uses, such as in the carriage or automobile supply trade, the upholstering trade, the different shoe or shoe finding trades, novelty leather articles and others of the same general character.

In the drawing accompanying and forming part of the present specification, I have shown an article involving the invention, This drawing also illustrates a wa of carrying the method into effect. eferring more specifically to the same, Figure 1 IS a perspective view of an article made in accordance with the method; Fig. 2 is a cross section of the same; and Fig. 3 is a like view of another form. Like characters refer to like parts throughout the several views.

l have several primary motives in view, probably the principal ones of them being the cheapening in cost of producing these various artificial leathers, and at the same time rendering. them especially durable and secure in their composition and at the same time the tenacity of their coatings to their anchorage of Whatever nature the same may be, the anchorage preferably but not essentially comprising a cloth base.

It is a matter of fact that artificial leathers at the present date are confined practi cally to two general classes; to cloths coated with the so-called pyroxylin films, and to cloths coated with oxidized oil preparations which do not contain pyroxylin. Various manufacturers use one or the other modified according to their methods or idea? suitaple to their requirements. Investigators and workers in this field have considered combining and have combined these dissimilar coatings; patents have been obtained for modifications of them, as for instance the use of intermediate coatings of oil between pyroxylin films to cheapen the cost of manufacture. My invention it might be noted at this particular point relates to a somewhat similar though vitally and decidedly difiercut and specifically defined method of securing results claimed.

his a Well-known fact in the trade that with the coatings referred to as the pyroxylin films, there is a decided tendency to detach or peel from the cloth base. This is caused, at times, by rapid evaporation. of

the solvent at time of coating, making necessary an extravagant expenditure of film at that time, or it is caused by the action of the atmosphere later, decomposing the non drying oil in the film. The coatings which I have referred to as oxidized oil prepare..- tions do not peel but have, however, the

fatal tendency when many coats have been superposed one upon the other, of cracking under the action of time, or if subjected to sharply defined bending and pressure of also cracking whatever coats of japan or other finish may be placed upon them.

My invention relates to a combination of the two coatings in question applied in such a Way that the peeling trouble is obviated fully and permanently, as the anchorage to the base, generally of cloth, of the entire number of films of coating is made secure and final. I might note also that the combinations of coatings applied in accordance with my method (in the finished product} 'will be softer and more pliable than that of the pyroxylin coatings by themselves. The" resultant article made in accordance with my method is as'a matter of fact more durable than one having applied thereto a series of oil coatings alone; at the same time I secure a surface which may be embossed (not possible by the present oil method) and also one which may be efiiciently ja panned. This combination of coatings being japanned obviates another serious defeet usually present in cloths coated with pyroxylin-an intensely disagreeable odor. The non-drying oil wrapped in the roll, bewmes rancid from decomposition or from similar action; by this method the pyroxylin coatings in artificial patent leather are locked between two covers each impervious to air. and moisture. These results are also secured at a lower cost than under any other method at present in use. In this case the lie decreased cost is insured by the economy of a single anchorage coat of oxidized linseed oil during which application practically no evaporation of solvent takes place as when the far more expensive pyroxylin film is used (frequently several coats of the latter are necessary for anchorage), and later the pyroxylin films can be reduced in number.

In practising my method I may employ as will be inferred a suitable base such as a cloth base of sheeting weave, that is one in which woof and warp are woven equally, so that strain or wear will be evenly distributed, or in other words the cloth will not stretch more in one direction than in another. On this cloth base is placed by coating machine operated by knife or slicker plan, a coating prepared from linseed oil after the approved methods of the leather working trades in making sweetmeats. This oil is desirably oxi dized. If the oxidization is produced by boiling, the latter should be not less than twenty hours and at a maximum temperature of 270 degrees C. without lead drier, though three per cent. of manganese borate may be .used until when cooled it becomes practically of the consistency of crude rubber. This coating material when cool is thinned to homogeneous mixture with the solvent used in the pyroxylin films to follow. In, this case I will say that pyroxylin and castor oil are dissolved in acetone and its diluents; then the same solvent will be used for the oxidized oil coat.

It will not perhaps be necessary to use coloring in the linseed oil as the subsequent coatings, several in number, will decide the color, but if necessary to color, grind in the color with the oil when the latter is nearly solid, then thoroughly dissolve until about a soft jelly consistency. The consistency should be such that the coating will permeate the fibers yet not penetrate to the backof the cloth. The cloth is coated at a tension, one light coat having been found sufficient. The cloth is not to be rolled at the time of thus coating, but should be passed to a drying room and festooned until thoroughly dry. At 120 degrees F. twentyfour hours is enough, although a longer time is desirable. This requires two procedures but obviates the necessity for expensive coating machines which have drying chambers. It is Within the bounds of possibility that I might use other Ways of drying coated fabric. \Vhen the coated fabric is thoroughly dried. it is run through calender rollers which I have found to be a strict requirement at this particular proceeding. The calendering in the present case is intended to soften the texture of the fabric and to prevent any unevenness in the coat that might thereafter affect the ensuing coat or coats. From the calender rollers the coated material is introduced into a coating machine which adds the pyroxylin film. The application of this film it is not necessary for me to describe.

It will be found that the light oil filling coat dried and calendered has not only waterproofed but softened and made more pliable the leather-like the entire fabric, whereas the pyroxylin film formerly used as anchorage has hardened the cloth and given to it a wiry brittle feel. Carrying the process to the point of finish or japanning (any good linseed oil varnish will answer) then the varnish covering acting in conjunction with the oxidized oil first coat described. locks between the two the intermediate pyroxylin films, preventing the action of the air upon the latter, adding thus not only to the life of the fabric but freeing it at the same time from an unpleasant feature, an

odor so disagreeable as to detract from its commercial value.

Referring particularly to Figs. 1 and 2 of the drawings, 2 denotes a base of some textile material such as cotton cloth. Upon the base 2- of whatever character the same may be, is an oil coating 3, the oil being oxidized and usually being linseed oil. On the oil coating 3- is applied a pyroxylin film as -'l.

In Fig. 3, the base 5 may be exactly the same as the base -2 and the coating 6 may be also precisely like the coating 3-. The only striking difference between the article of Fig. 3 and that shown in Figs. 1 and 2 is that there are several coats of pyroxylin film 7, 8, 9-, and 10-, four of them being shown, although this may not always be necessary as will be clear.

\Vhat I claim is:

1. A method of making artificial leather which comprises coating a base of textile fabric with an oxidized oil coat having a solvent which is a solvent for pyroxylin, and applying a pyroxylin film to the coated base. having a solvent which is also a solvent for the oxidized oil coat.

'2. A method of producing artificial leather which comprises applying a coating of oxidized linseed oil to a suitable base. drying the base and coating, calendcring the coated base, applying a pyroxylin film to the coated surface. and then applying a varnish to the pyroxylin coated surface.

3. A method of producing artificial leather which comprises coating a base of textile material with oxidized oil having a solvent and applying a pyroxylin film to the coated base, having a solvent which is the same as that of the oil coat.

4. A method of producing artificial leather which comprises directly coating a base of textile material with oxidized oil having a solventdrying and calcndering the base and then after calendering the base applying a pyroxylin film having a solvent which is the same as that of the oil coat- 5. A method of producing artificial leather which comprises coating a base of textile material with oxidized oil having a solvent and then applyingthereto a succession .of coats of pyroxylin each of which has a solvent the same as that of the oil coat.

6. A method of making artificial leather which comprises directly coating 3, base of textile material with oxidized linseed oil having a solvent, drying and calendering the base and then after calendering the base applying thereto several coatings of pyroxylin each having a solvent which is the same as that of the oil coat.

7. A method of making artificial leather which comprises directly coating a textile base with oxidized linseed oil having a solvent, drying and calendering the base and then after calendering the base applying thereto several coatings of pyroxylin each having a solvent which is the same as that of the oil-coat.

8. A method of making artificial leather [scan] which comprises directly coating a textile base with oxidized linseed oil having a solvent, drying and calendering the base, then after calendering the base applying thereto several coatings of pyroxylin each having a solvent which is the same as that of the oil coat, and then japanning the coated base.

9. An artificial leather comprising a base of textile material having a coating of oxidized oil directly applied thereto and a pyroxylin film superimposed upon the oil coating, the two having been applied with a solution having a common solvent.

10. An artificial leather comprising a base of textile material having a coating of oxidized oil directly applied thereto and a pyroxylin film superimposed upon the oil coating, the two having been applied with a solvent of both coatings.

In testimony whereof I afiix my signature in the presence of two witnesses.

RICHARD F. DYER.

Witnesses:

EDWARD A. HAVENS, Gm. H. BERRY.

It is hereby certified that Letters Patent No. 1,308,231, granted July'l, 1919, upon the application of Richard F. Dyer, of Providence, Rhode Island, for an improvement in Artificial Leather and Method of Producing It, to George H. Gabb as owner of the entire interest in said invention,

were erroneously issued whereas said Letters Patent should have been issued to the inventor, said Dyer and George H. Gabb, jointly, said Gabb being assignee of one-half interest only in said invention, as shown by the records of assignments in this ofiice; and that the said Letters Patent should be read with this correction therein that the same may conform to the record of the case in the Patent Oflice.

Signed and sealed this 5th day of August, A. D., 1919.

R. F. WHITEHEAD,

Acting Commissioner of Patents. 

